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Ford Ranger
Ford Ranger
25 MY
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TIE42918
TIA2301151
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GROUP
General Information 1
SECTION TITLE PAGE
Service Information
General Information.......................................................................................................100-00
Identification Codes.......................................................................................................100-01
Jacking and Lifting.........................................................................................................100-02
Noise, Vibration and Harshness....................................................................................100-04
2011.50 BT50
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Workshop Manual
Table of Contents
GROUP 1 General Information GROUP 3 Powertrain
Service Information Engine
General Information 100-00 Engine System - General
Identification Codes 100-01 Information 303-00
Jacking and Lifting 100-02 Engine - 2.5L Duratec-HE
Noise, Vibration and (122kW/165PS) - MI4 303-01A
Harshness 100-04 Engine - 2.2L Duratorq-TDCi
(88kW/120PS) - Puma/2.2L
GROUP 2 Chassis Duratorq-TDCi (96kW/130PS) -
Puma/2.2L Duratorq-TDCi
Suspension (110kW/150PS) - Puma 303-01B
Engine - 3.2L Duratorq-TDCi
Suspension System - General (148kW/200PS) - Puma 303-01C
Information 204-00 Engine Cooling - 2.2L Duratorq-TDCi
Front Suspension 204-01 (88kW/120PS) - Puma/2.2L
Rear Suspension 204-02 Duratorq-TDCi (96kW/130PS) -
Wheels and Tires 204-04 Puma/2.2L Duratorq-TDCi
Driveline (110kW/150PS) - Puma 303-03A
Driveshaft 205-01 Engine Cooling - 3.2L Duratorq-TDCi
Rear Drive Axle/Differential 205-02 (148kW/200PS) - Puma 303-03B
Front Drive Axle/Differential 205-03 Engine Cooling 303-03C
Front Drive Halfshafts 205-04 Fuel Charging and Controls - 2.5L
Rear Drive Halfshafts 205-05 Duratec-HE (122kW/165PS) -
Brake System MI4 303-04A
Brake System - General Fuel Charging and Controls - 2.2L
Information 206-00 Duratorq-TDCi (88kW/120PS) -
Drum Brake 206-02 Puma/2.2L Duratorq-TDCi
Front Disc Brake 206-03 (96kW/130PS) - Puma/2.2L
Parking Brake and Actuation 206-05 Duratorq-TDCi (110kW/150PS) -
Hydraulic Brake Actuation 206-06 Puma 303-04B
Power Brake Actuation 206-07 Fuel Charging and Controls - 3.2L
Anti-Lock Control 206-09A Duratorq-TDCi (148kW/200PS) -
Anti-Lock Control - Traction Puma 303-04C
Control 206-09B Fuel Charging and Controls -
Turbocharger 303-04D
Steering System Accessory Drive - 2.5L Duratec-HE
Steering System - General (122kW/165PS) - MI4 303-05A
Information 211-00 Accessory Drive - 2.2L Duratorq-TDCi
Power Steering 211-02 (88kW/120PS) - Puma/2.2L
Steering Linkage 211-03 Duratorq-TDCi (96kW/130PS) -
Steering Column 211-04 Puma/2.2L Duratorq-TDCi
Steering Column Switches 211-05
2011.50 BT50
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FOREWORD
Copyright ©
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5
Front Wheel Alignment
6
Rear Wheel Alignment
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*1 : Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2 : Difference between left and right must not exceed 1°30′.
Standard length L
11.1—29.1 mm {0.44—1.14 in}
Tightening torque
68—92 N·m {7.0—9.3 kgf·m, 51—67 ft·lbf}
6. Verify that the boot is not twisted, and install the boot abs0zw00000589
clamp.
7. Adjust the toe-in after adjusting the steering angle.
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Camber Adjustment
1. Loosen the front upper arm nut. FRONT
UPPER
ARM
NUT
abs0zw00000590
2. Loosen the fixing nut of the adjusting cam bolt (front 4x2 (EXCEPT HIGH CLEARANCE
lower arm). MODEL)
FIXING NUT
FIXING NUT
abs0zw00001252
3. Rotate the adjusting cam bolt in either direction to adjust the camber.
4×2 (Except high clearance model)
Left wheel Right wheel LEFT WHEEL FRONT OF RIGHT WHEEL
Camber Front Front VEHICLE
Rear cam Rear cam TOP OF TOP OF
cam cam VEHICLE VEHICLE
Positive Counter- Counter-
Clockwise Clockwise
direction clockwise clockwise
Negative Counter- Counter-
Clockwise Clockwise
direction clockwise clockwise
POSITIVE POSITIVE
ADJUSTING
CAM BOLT
TOP OF TOP OF
VEHICLE VEHICLE
ADJUSTING
CAM BOLT
POSITIVE POSITIVE
abs0zw00000592
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Tightening torque
141—189 N·m {15—19 kgf·m, 104—139 ft·lbf} ADJUSTING
CAM BOLT
5. Tighten the the fixing nut of the adjusting cam bolt
(front lower arm).
abs0zw00001253
Caster Adjustment
1. Loosen the front upper arm nut. FRONT
UPPER
ARM
NUT
abs0zw00000590
2. Loosen the fixing nut of the adjusting cam bolt (front 4x2 (EXCEPT HIGH CLEARANCE
lower arm). MODEL)
FIXING NUT
FIXING NUT
abs0zw00001252
3. Rotate the adjusting cam bolt in either direction to adjust the caster.
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Tightening torque
141—189 N·m {15—19 kgf·m, 104—139 ft·lbf} INCREASE INCREASE
5. Tighten the the fixing nut of the adjusting cam bolt abs0zw00000593
ADJUSTING
6. Adjust the total toe-in. (SeeTotal Toe-in CAM BOLT
Adjustment.)
INCREASE INCREASE
ADJUSTING
CAM BOLT
TOP OF TOP OF
VEHICLE VEHICLE
INCREASE INCREASE
abs0zw00001254
Note
• Toe angle changes by approx. 6 mm {0.2 in} per one rotation of the tie rod for one wheel.
• Each tie rod has a right-hand thread. When increasing the toe-in angle, rotate the right tie rod toward the
front of the vehicle and rotate the left tie rod toward the rear of the vehicle by the same amount.
Tightening torque
68—92 N·m {7.0—9.3 kgf·m, 51—67 ft·lbf}
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*1 : Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
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Purpose/Function
• This valve is used to allocate the braking force to the front and rear wheels as ideally as possible for higher safety
when the brakes are applied, it controls the brake fluid pressure to the rear brakes according to the load on the
rear axle so that the rear end of the vehicle does not spin due to the locking of the rear wheels in advance of the
front wheels.
• This valve also incorporates a bypass passage that prevents pressure reduction so that rear wheels will still have
enough braking force to stop the vehicle in the event of a front master cylinder malfunction.
Construction
BREATHER
RING VALVE VALVE
X-RING
PLUNGER
MAIN SPRING
AXLE L
L CASING
ADJUSTING LINK
ADJUSTING LINK
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Operation
Braking When Vehicle Empty
• The hydraulic pressure generated at the front section of the master cylinder is applied, via input port 1, to the
hydraulic-pressure control section of the LSPV.
• The hydraulic pressure generated at the rear section of the master cylinder is applied to the front brakes, and to
the bypass section of the LSPV via input port 2. The rear wheel and front wheel hydraulic pressure are separated
by the X-ring of the plunger. Since port 1 hydraulic pressure is normally equal to port 2 hydraulic pressure, the
plunger is pressed against the cylinder base by L.
• When port 1 hydraulic pressure is applied to the plunger, the plunger tries to move to the left. But, because there
is also at the same time force applied in the right direction by the lever link (force L), the plunger is held against
the cylinder base. The result is that the hydraulic pressure at the output side is the same as at the input side
when force L is higher than the input pressure.
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PRESSURE IN PRESSURE IN
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• When the input hydraulic pressure increases further and overcomes force L, the plunger is moved slightly
leftward, sealing it against the ring valve. This temporarily separates the input side from the output side. The
output pressure at this time is called the break point. If force L from the lever link changes (i.e. lowering of the
vehicle body), this break point changes accordingly.
PRESSURE IN PRESSURE IN
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OUTPUT PRESSURE
kP
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PLUNGER RING VALVE
AXLE CASING
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• When the input pressure passes the break point, the plunger is moved back against the cylinder base. The output
port is opened, and hydraulic pressure generated at the rear section of the master cylinder is applied to the rear
wheel cylinders.
• As the output pressure continues to increase, the plunger is again moved toward the left against the ring valve,
thus separating the input and output side again.
• This action is repeated to control the output pressure.
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Powertrain 3
SECTION TITLE PAGE
PAGE 1 OF 2
Engine
Engine System - General Information............................................................................303-00
Engine2.5L Duratec-HE (122kW/165PS) - MI4.............................................................303-01A
Engine2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
(96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma........................303-01B
Engine3.2L Duratorq-TDCi (148kW/200PS) - Puma.....................................................303-01C
Engine Cooling2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
(96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma........................303-03A
Engine Cooling3.2L Duratorq-TDCi (148kW/200PS) - Puma........................................303-03B
Engine Cooling..............................................................................................................303-03C
Fuel Charging and Controls2.5L Duratec-HE (122kW/165PS) - MI4............................303-04A
Fuel Charging and Controls2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L
Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) -
Puma..........................................................................................................................303-04B
Fuel Charging and Controls3.2L Duratorq-TDCi (148kW/200PS) - Puma....................303-04C
Fuel Charging and Controls - Turbocharger..................................................................303-04D
Accessory Drive2.5L Duratec-HE (122kW/165PS) - MI4..............................................303-05A
Accessory Drive2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
(96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L
Duratorq-TDCi (148kW/200PS) - Puma.....................................................................303-05B
Starting System2.5L Duratec-HE (122kW/165PS) - MI4...............................................303-06A
Starting System2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
(96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L
Duratorq-TDCi (148kW/200PS) - Puma.....................................................................303-06B
Engine Ignition2.5L Duratec-HE (122kW/165PS) - MI4.................................................303-07A
Glow Plug System2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
(96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma........................303-07B
Glow Plug System3.2L Duratorq-TDCi (148kW/200PS) - Puma...................................303-07C
Engine Emission Control2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L
Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) -
Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma..................................................303-08A
Engine Emission Control................................................................................................303-08B
Intake Air Distribution and Filtering2.5L Duratec-HE (122kW/165PS) - MI4.................303-12A
Intake Air Distribution and Filtering2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L
Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) -
Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma..................................................303-12B
Evaporative Emissions...................................................................................................303-13
Electronic Engine Controls2.5L Duratec-HE (122kW/165PS) - MI4..............................303-14A
Electronic Engine Controls2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L
Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) -
Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma..................................................303-14B
2011.50 BT-50
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PAGE 2 OF 2
Automatic Transmission/Transaxle
Automatic Transmission/TransaxleVehicles With: 6-Speed Automatic Transaxle -
6R80...........................................................................................................................307-01
Transmission/Transaxle Cooling....................................................................................307-02
Automatic Transmission/Transaxle External Controls...................................................307-05
Manual Transmission/Transaxle, Clutch and Transfer Case
Manual Transmission/Transaxle and Clutch - General Information...............................308-00
ClutchVehicles With: 5-Speed Manual Transmission - MT75........................................308-01A
ClutchVehicles With: 6-Speed Manual Transmission - MT82........................................308-01B
Clutch ControlsVehicles With: 5-Speed Manual Transmission - MT75.........................308-02A
Clutch ControlsVehicles With: 6-Speed Manual Transmission - MT82.........................308-02B
Manual Transmission/TransaxleVehicles With: 5-Speed Manual Transmission -
MT75..........................................................................................................................308-03A
Manual Transmission/TransaxleVehicles With: 6-Speed Manual Transmission -
MT82..........................................................................................................................308-03B
Manual Transmission/Transaxle External ControlsVehicles With: MT-75.....................308-06A
Manual Transmission/Transaxle External ControlsVehicles With: MT82.......................308-06B
Transfer CaseVehicles With: 5-Speed Manual Transmission - MT75/6-Speed Manual
Transmission - MT82..................................................................................................308-07A
Transfer CaseVehicles With: 6-Speed Automatic Transaxle - 6R80.............................308-07B
Exhaust System
Exhaust System2.5L Duratec-HE (122kW/165PS) - MI4..............................................309-00A
Exhaust System2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
(96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L
Duratorq-TDCi (148kW/200PS) - Puma.....................................................................309-00B
Fuel System - General Information
Fuel System - General Information2.5L Duratec-HE (122kW/165PS) - MI4.................310-00A
Fuel System - General Information2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L
Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) -
Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma..................................................310-00B
Fuel Tank and Lines.......................................................................................................310-01A
Fuel Tank and Lines2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
(96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L
Duratorq-TDCi (148kW/200PS) - Puma.....................................................................310-01B
Acceleration Control.......................................................................................................310-02
2011.50 BT-50
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SECTION TITLE PAGE
Service Information
General Information.......................................................................................................100-00
Identification Codes.......................................................................................................100-01
Jacking and Lifting.........................................................................................................100-02
Noise, Vibration and Harshness....................................................................................100-04
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Chassis 2
SECTION TITLE PAGE
Suspension
Suspension System - General Information....................................................................204-00
Front Suspension...........................................................................................................204-01
Rear Suspension...........................................................................................................204-02
Wheels and Tires...........................................................................................................204-04
Driveline
Driveshaft.......................................................................................................................205-01
Rear Drive Axle/Differential............................................................................................205-02
Front Drive Axle/Differential...........................................................................................205-03
Front Drive Halfshafts....................................................................................................205-04
Rear Drive Halfshafts.....................................................................................................205-05
Brake System
Brake System - General Information..............................................................................206-00
Drum Brake....................................................................................................................206-02
Front Disc Brake............................................................................................................206-03
Parking Brake and Actuation.........................................................................................206-05
Hydraulic Brake Actuation..............................................................................................206-06
Power Brake Actuation..................................................................................................206-07
Anti-Lock Control...........................................................................................................206-09A
Anti-Lock Control - Traction Control...............................................................................206-09B
Steering System
Steering System - General Information..........................................................................211-00
Power Steering...............................................................................................................211-02
Steering Linkage............................................................................................................211-03
Steering Column............................................................................................................211-04
Steering Column Switches.............................................................................................211-05
2011.50 BT-50
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1096 {43.15}
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934 {36.8}
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969 {38.2}
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666 {26.2}
669 {26.3}
194 134
{7.64} {5.28}
STRAIGHT-LINE DIMENSIONS
1008 {39.69}
{70.28} 1131 {44.53}
1556 {61.26} 1162
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datum hole
size mm {in}
20 × 26
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size mm {in}
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mm {in}
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1036 {40.79}
1270 {50.00}
1244 {48.98}
1096 {43.15}
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942 {37.1}
934 {36.8}
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966 {38.0}
973 {38.3}
933 {36.7}
869 {34.2}
875 {34.4}
839 {33.0}
588 {23.1}
669 {26.3}
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1131 {44.53}
1556 {61.26} 1162
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size mm {in}
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Cabin mounting bracket No.2
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Removal
1. Refer to: Battery Disconnect and Connect.
2. Refer to: Front Bumper Cover.
3. Refer to: Headlamp Assembly.
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FRAME DIMENSIONS (UNDERBODY FREESTYLE CAB 2WD HIGH CLEARANCE MODEL) [DIMENSIONS]
id098010618100
FLAT-PLANE DIMENSIONS
mm {in}
1248 {49.13}
1270 {50.00}
1244 {48.98}
1244 {48.98}
1096 {43.15}
LH
942 {37.1}
934 {36.8}
RH
A B C D E F G' H I
1019 {40.12}
966 {38.0}
973 {38.3}
933 {36.7}
866 {34.1}
839 {33.0}
785 {30.9}
969 {38.1}
669 {26.3}
155 134
{6.10} {5.28}
1008 {39.69}
1131 {44.53}
1556 {61.26} 1162
F
{45.75}
1116
A B {43.94} I
E H
C D
abs0zb00000006
f- - - -I----+--
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Point Point
Designation or bolt or nut Designation or bolt or nut
symbol symbol
I I
H
Box mounting bracket No.3
datum hole
size mm {in}
20 × 26
{0.79 × 1.0}
I Side member datum hole
size mm {in}
ø6.5 {0.26}
MAZDA BT50 WORKSHOP REPAIR MANUAL 2012.25 MY
FLAT-PLANE DIMENSIONS
mm {in}
1248 {49.13}
1314 {51.73}
1244 {48.98}
1244 {48.98}
1096 {43.15}
LH
942 {37.1}
934 {36.8}
RH
A B C D E F G' H I
1019 {40.12}
966 {38.0}
973 {38.3}
933 {36.7}
969 {38.2}
869 {34.2}
839 {33.0}
670 {26.4}
669 {26.3}
194 134
{7.64} {5.28}
STRAIGHT-LINE DIMENSIONS
1008 {39.69}
{70.28} 1131 {44.53}
1556 {61.26} 1162
F
{45.75}
1116
A B {43.94} I
E H
C D
abs0zb00000002
f- - - -I----+--
+- I
Point Point
Designation or bolt or nut Designation or bolt or nut
symbol symbol
I I
H
Box mounting bracket No.3
datum hole
size mm {in}
20 × 26
{0.79 × 1.0}
I Side member datum hole
size mm {in}
ø6.5 {0.26}
MAZDA BT50 WORKSHOP REPAIR MANUAL 2012.25 MY
FRAME DIMENSIONS (UNDERBODY REGULAR CAB 2WD HIGH CLEARANCE MODEL) [DIMENSIONS]
id098010618400
FLAT-PLANE DIMENSIONS
mm {in}
1248 {49.13}
1314 {51.73}
1244 {48.98}
1244 {48.98}
1096 {43.15}
LH
942 {37.1}
934 {36.8}
RH
A B C D E F G' H I
1019 {40.12}
966 {38.0}
973 {38.3}
933 {36.7}
969 {38.2}
869 {34.2}
839 {33.0}
670 {26.4}
669 {26.3}
194 134
{7.64} {5.28}
STRAIGHT-LINE DIMENSIONS
1008 {39.69}
{70.28} 1131 {44.53}
1556 {61.26} 1162
F
{45.75}
1116
A B {43.94} I
E H
C D
abs0zb00000003
f- - - -I----+--
+- I
Point Point
Designation or bolt or nut Designation or bolt or nut
symbol symbol
I I
H
Box mounting bracket No.3
datum hole
size mm {in}
20 × 26
{0.79 × 1.0}
I Side member datum hole
size mm {in}
ø6.5 {0.26}
MAZDA BT50 WORKSHOP REPAIR MANUAL 2012.25 MY
FRAME DIMENSIONS (UNDERBODY DOUBLE CAB 2WD HIGH CLEARANCE MODEL) [DIMENSIONS]
id098010619000
FLAT-PLANE DIMENSIONS
mm {in}
LH
1248 {49.13}
1036 {40.79}
1270 {50.00}
1244 {48.98}
1096 {43.15}
942 {37.1}
934 {36.8}
RH
A B C D E F G' H I
1019 {40.12}
966 {38.0}
973 {38.3}
933 {36.7}
869 {34.2}
871 {34.3}
839 {33.0}
588 {23.1}
669 {26.3}
135
{5.31}
STRAIGHT-LINE DIMENSIONS
1008 {39.69}
1131 {44.53}
1556 {61.26} 1162
F
{45.75}
1116
A B D
{43.94} I
H
C E
abs0zb00000007
Hole diameter
Point
Designation or bolt or nut
symbol
size mm {in}
Cabin mounting bracket No.1
A ø15.25 {0.6004}
datum hole
B Upper arm bracket datum hole ø28.9 {1.14}
Cabin mounting bracket No.2
C ø38.65 {1.522}
datum hole
D Side member datum hole ø6 {0.2}
MAZDA BT50 WORKSHOP REPAIR MANUAL 2012.25 MY
Hole diameter
Point
Designation or bolt or nut
symbol
size mm {in}
Cabin mounting bracket No.3
E ø38.65 {1.522}
datum hole
F Damper bracket -
G’ Damper bracket -
Box mounting bracket No.3 20 × 26
H
datum hole {0.79 × 1.0}
I Side member datum hole ø6.5 {0.26}
MAZDA BT50 WORKSHOP REPAIR MANUAL 2012.25 MY
1
3
1799 {70.83}
1543 {70.83}
1516 {59.69}
6
4
5
mm {in}
abs0zb00000013